subscriber briefing · 3. compliance/job audits o ndt: 3 witnessed compliance jobs per method and 3...
TRANSCRIPT
Subscriber Briefing
Joe Pinto – Executive Vice President & Chief Operating Officer
Agenda
• Nadcap Overview
• Membership Responsibilities
• Membership Benefits
• Membership Cost
PRI is a not-for-profit affiliate of SAE International
PRI administers the Nadcap special processes accreditation program and PRI Registrar on behalf of its Subscribing Members and industry
Nadcap created by aerospace Original Equipment Manufacturers (OEMs or Primes) to provide supply chain oversight and ensure regulatory compliance
Nadcap uses audit management software created and maintained in-house by PRI Informatics Solutions (eAuditNet)
Complementary programs, tools, and professional development services created by PRI to support Nadcap
3
PRI Mission Statement
PRI is a global provider of customer focused solutions designed to improve process and product quality by adding value, reducing total cost and promoting collaboration among stakeholders in industries where safety and quality are shared goals.
4
PRI Leadership
PRI is led by a Board of Directors with
responsibility for strategic direction and
financial stability.
The Board is comprised of leading Quality
Executives from some of the world’s largest
aerospace companies.
PRI Board of Directors Stan Adachi
Director, BDS Supplier Quality Boeing Defense, Space and Security
Robert Briggs Manager Supply Chain Quality GE Aircraft Engines
David Handley (Chairman) Head of Quality BAE Systems (Operations) Limited
Michael Hayward Sector Director Product Quality, Aerospace
Systems Northrop Grumman Corp.
Mario Langlois Aerospace Quality Director Bombardier
Jean-Jacques Orsini Vice President Quality Snecma
Andy Page Global Supplier Development Executive Rolls-Royce plc
John Papadopoulos Director Quality & Continuous Improvement
United Technologies Corporation
David L. Schutt Chief Executive Officer
SAE International
Kristin Slyker Vice President, Commercial Customer Operations
Honeywell Aerospace
Junji Tsuji General Manager of Engineering Group
Ishikawajima-Harima Heavy Industries Co.
Bernard Veyssière Vice President Quality
EADS
Steve Wells VP Quality& Continuous Improvement
Goodrich
Li Wei General Director, Quality and Safety Department
Aviation Industry Corporation of China
6
PRI Brands
Accreditation
• Special Process, Systems and Products
• Industry Managed
• NUCAP uses the same Nadcap process , but is for OEMs only
Professional Development
• Programs and managed learning resources
• To improve the quality of personnel, products and processes
AS9100
ISO9000
ISO14001
• One-Stop-Shop
• Improving the quality of
• Personnel
• Products & Processes
List of Qualifying Aerospace Products
• Similar to Nadcap
• Focuses on Products rather than processes
7
Complementary
PRI Historical Highlights
8
1985 Government/Industry Equal Partner Conference identifies the need to minimize redundant audits.
1990 SAE launches PRI as a separately incorporated 501(c)6. Nadcap launched. 5 NDT audits conducted.
1992 GEAE and Allied Signal mandate Nadcap. 70 NDT audits conducted.
1994 Heat treat, welding, chemical processing, coatings, material test labs have been added.
2000 Nadcap Europe established with U.K. office
2002 Airframers (Airbus, Boeing, Bombardier, Cessna) join PRI and mandate Nadcap. Nadcap business support software launched.
2003 Nadcap Asia launched. Detroit Big 3 take Nadcap concept to AIAG.
2008 PRI launches Professional Development programs.
2010 Renewed focus on the Supplier.
2011 Reposition PD as a service. Focus on globalization. Investigate new aerospace areas and industry models.
9
Nadcap Defined
9
The leading, worldwide industry-managed cooperative program of major companies designed to manage a cost effective consensus approach to special processes and products and provide continual improvement within the aerospace industry.
9
Compliance – Control – Cost Savings – Risk Reduction
Nadcap Model
• Primes (OEMs) work to reach consensus on core audit criteria
• Supplier identifies need for accreditation to Prime requirements
• Subject-matter experts, managed jointly by PRI and Primes, conduct audit to industry requirements
• PRI Staff Engineers review non-conformance findings and work with supplier to identify and execute corrective actions
• Primes, organized into technology-specific Task Groups, review audit packages and issue accreditations, once all findings are resolved
• Primes work with PRI to measure program activity and continually improve the program 10
What are Special Processes?
• Processes which: – Modify or change the inherent physical, chemical, electrical or
metallurgical properties of an item, or
– Non-conventional methods which remove or deposit material on an item during or after fabrication which cannot be fully evaluated by nondestructive means, or
– Those used to maintain process control such as nondestructive testing.
• These processes may require a demonstration of operator or equipment capability or proficiency and require special controls for monitoring per specification.
• Means for compliance are contained in individual specifications.
11
Nadcap Accreditation Today
12
Special Processes Systems & Products
Non-Destructive Testing
Welding
Chemical Processing
Heat Treating
Coatings
Non-Conventional Machining
Conventional Machining
Surface Enhancement
Aerospace Quality Systems
Composites
Materials Testing
Nonmetallic Material Testing
Electronics
Fluid Distribution Systems
Sealants
Seals
Nadcap Customers
Subscribers:
Manufacturers with design authority, requiring controls over supplier quality (OEMs, primes, Government Agencies, etc.)
Suppliers:
Companies providing special processes to Subscribers, who need their manufacturing controls audited
Nadcap Members • 309th Maintenance Wing – Hill AFB
• AgustaWestland
• Air Force
• Alenia Aeronautica SpA
• Avio SpA
• BAE Systems – Military Air Solutions (MAS)
• BAE Systems
• Ball Aerospace & Technology Corporation
• The Boeing Company
• Bombardier Inc.
• Defense Contract Management Agency (DCMA)
• EADS Corporation
– Airbus
– EADS CASA
– Eurocopter
– Astrium
– Cassidian
– Aerolia
– Premium Aerotech
• GE Aviation
• General Dynamics
• General Services Administration (GSA)
• Goodrich Corporation • Hawker Beechcraft Corporation
• Heroux Devtek Inc. (Landing Gear Division)
• Honeywell Aerospace
• Israel Aircraft Industries
• Latecoere
• Liebherr-Aerospace SAS
• Lockheed Martin Corporation
• M7 Aerospace LP
• MTU Aero Engines GmbH
• Northrop Grumman Corporation
• Parker Aerospace Group
• Raytheon Company
• Rockwell Collins, Inc.
• Rolls-Royce Corporation
• Rolls-Royce PLC
• SAFRAN Group
• Sonaca
• Spirit AeroSystems
• Textron Inc.
– Bell Helicopter
– Cessna Aircraft Company
– Textron Systems
• Thales
• Triumph Group Inc.
• United Technologies Corporation
– Hamilton Sundstrand
– Pratt & Whitney
– Pratt & Whitney Canada
– Sikorsky Aircraft
• Volvo Aero
1 4
1 1 3 4 3 4 4
2 2 1 1 1 1
1
5
2
13
2 2
1 0
10
20
30
40
50
60
70
0
2
4
6
8
10
12
14
16
18
Acc
um
ula
ted
To
tal P
rim
es
Ne
w P
rim
es
pe
r Ye
ar
Year
Americas Europe
Timeline of Primes
Hawker Beechcraft
Pratt & Whitney (US) Pratt & Whitney (Canada) GE Sikorsky
Honeywell
RR plc
RR Corp AVIO
Northrop Grumman GSA Hamilton Sundstrand
Vought Bell Helicopter DCMA Cessna
Boeing MD Helicopters Lockheed Martin Airbus
EADS MTA Eurocopter EADS Astrium EADS Defense
Goodrich Alenia BAE Systems (US) Rockwell Collins Bombardier SONACA
MTU
SAFRAN Group (Snecma Services, Hispano-Suizo, Aircelle, Messier-Bugatti, Messier-Dowty, Messier-Services, Labinal, Techspace Aero, Snecma Propulsion Solide, Microturbo, Cinch and Globe Motors) Latecore Liebherr Spirit Textron Systems Ball Aerospace Heroux Devtek
BAE MAS Thales Parker Aerospace Group United Space Alliance
Volvo Aero Corp. Genl. Dynamics IAI
309th Maint. Wing-Hill AFB Raytheon Co. Agusta
Westland
M7 Aerospace
Nadcap Organizational Structure
Strategic
Tactical
Technical
Technical Experts •Determine requirements •Develop documents •Accept corrective action •Final decision on accreditation
Task Groups Special Processes
Nondestructive Testing, Materials Testing
Heat Treating, Coatings, Chemical Processing,
Welding, NMSE
Systems & Products Electronics,
Sealants, Elastomer Seals, AQS (AC7004),
Fluid Distribution Systems, Composites
Administrative Staff
Supplier Support Committee (SSC)
Nadcap Management Council (NMC)
Executive leaders •Legal entity •Fiduciary responsibility •Set policy •Provide the Vision
Senior quality leaders & managers •Oversee Nadcap operation •Establish & implement policy &
procedures •Task Group coordination & development •Continuous improvement
PRI Board of Directors
16
Status Report - Supplier Audits Composites 155 131 135 135 121 98
CP 907 857 847 724 699 693 130
CT 124 113 124 112 106 83 37
Distributors 9 13
ETG 79 66 42 15 5 6
FAST 3 2 0 0
Fluids 25 32 25 30 23 18 7
HT 839 786 741 697 653 646 211
MTL 212 178 185 209 149 173 135
NDT 1021 973 1000 953 962 897 303
NM 233 178 196 188 170 187
NMSE 4
NonMetallic Matls 24 20 10 6 1
Primes/other 15
SE 157 129 153 146 148 146
Seals 10 8 12 11 14 12 14
Sealants 12 17 12 12 15 16 10
WLD 464 411 446 403 416 400 148
Preassessments 85 71 41 26 31 13
NUCAP 223 187 181 138 137 43
Total 4,851 4,406 4,389 4,015 3,871 3,678 1,208
As of 07-OCT-11
Total Number of Audits
1208 1466
2437 2852
3295 3678
3870 4015 4389 4406
4851
0
1000
2000
3000
4000
5000
6000
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 YTD
No
. of
Au
dit
s
As of 09 Sep 2011
Audit Checklist
Industry experts manage all key steps
Shared Program Management
PRI and Industry Working Together
Primes/OEMs Suppliers PRI Staff
Establish
Audit
Criteria
Audit Criteria (AC):
Document containing checklists or other surveillance tools to be utilized in the course of determining compliance to established
industry standards and Primes/OEMs requirements.
Audit Checklist
Industry experts manage all key steps
Shared Program Management
Auditor Qualification & Selection
Auditor Qualification & Selection Selection/Interview/Performance
• Core and Technical Requirements are established by PRI, with OEM/Industry Council approval
• Potential candidates complete a pre-screening questionnaire and interviewed by PRI
• Testing/Certification (Optional)
• Training Audits and review of training with Report from Lead Auditor
• Approval by PRI
• Continual Monitoring through Audit Reviews
• Continuing Training
Current Nadcap Auditors:
• Average over 30 years of experience
• Over two-thirds hold B.S. Degrees
• Certified to meet International requirements, when required by Task Group
• Over a dozen hold PhDs
Audit Checklist
Industry experts manage all key steps
Shared Program Management
Audit Conducted
Auditor Qualification & Selection
Audit Content
1. Quality Systems
2. Special Process and Product Specific Requirements
3. Compliance/Job Audits
o NDT: 3 Witnessed Compliance Jobs per Method and 3 “Paperwork” Completed Compliance Jobs per Method
o Heat Treating: 2 Long Jobs-8 Short Jobs
o Materials Lab: Witnessing of All Test Methods
o Chemical Processing: Minimum of 4 Job Audits
o Coatings: 2-11 Job Audits (Based on Scope)
o Welding: 2 Job Audits per Method
o Nonconventional Machining: 2-10 Job Audits
o Surface Enhancement: 2-6 Job Audits
o Composites: 15-30 Job Audits (Based on Manufacturing Flow)
o Electronics: Complete 1 Job Audit
o Conventional Machining: 2-14 Job Audits (Based on Scope)
24
General Focus Audits and Nadcap
25
General Focus Audits Nadcap
•Written evidence of a quality system is required
•Quality system is verified (AS9100, AS9110, AC7004)
•Audit checklists are one-size-fits-all •All interested parties are given the opportunity to participate in checklist development through open meetings. •Checklists are based on industry standards.
•No operator certification •Operator is certified (where required)
•Inventory check •Involves actual job audits
•Single day audits •Audits take 3 – 5 days
•Findings are reviewed by auditor •Audits reviewed by experienced Staff Engineers and Task Group
•Reassessment audits conducted by the same auditor
•Different auditors assigned for each reassessment audit
•No traceability •Traceability through eAuditNet
Does the supplier define the process employed for the calibration of inspection, measuring and test equipment type, unique identification, location, frequency of
checks, check method, acceptance criteria and the action to be taken when results are unsatisfactory?
NDT Heat Treating Chemical Processing
General Focus Audit
Calibration:
NDT Heat Treating Chemical Processing
Are the FPI dryer ovens calibrated every three
months at multiple points across the usable range?
Are furnaces used for heat treating Aluminum
parts surveyed at the required tolerance and temperature range?
Is measuring and test equipment used to control or monitor the control of a
process (within parameters) maintained in a calibration system compliant with ISO
10012-1? (I.e. temperature gages, conductivity meters,
voltmeters, rectifiers)
Calibration:
PRI approach: Technical (Nadcap) Focus Audit
Audit Checklist
Industry experts manage all key steps
Shared Program Management
Audit Conducted
Audit Results
Corrective Actions
Auditor Qualification & Selection
NCR Classifications
• Major Nonconformance: – The absence of, or systemic breakdown of, the Process Control and/or
Quality Management system.
– Any non-conformance where the effect impacts or has the potential to impact the integrity of the product.
• Minor Nonconformance: – A non-systemic lapse in conformance to the Process Control and/or Quality
Management system.
Audit Review
PRI Staff Review: • Staff Reviews Package for Completeness
• Review Audit Report
– Clarification Changes - Contact Auditors for Clarification
– Review Supplier Corrective Action
– Close-Out or request additional information via Forums
• Audit Report Package is submitted via eAuditNet for Task Group Review
Task Group Review:
• Task Group decides Procedure for Review
• Task Group Reviews for Correctness
– Technical Comments, Supplier Responses, Technical Completeness, Auditor Summary Letter, Identify Additional Findings
• Completes Review of Each NCR and dispositions (NCR Status)
• Discuss Results with PRI
• Task Group Provides ultimate approval and acceptance
of audit package
Corrective Action Process
• Where no NCRs occurred, supplier completes feedback survey in eAuditNet • Suppliers with NCRs submits objective evidence of implementation for all
corrective actions • Staff Engineers review corrective actions • Audit Report Reviewers review the electronic audit report for completion and
accuracy within 14 days of the receipt of the response. • Audit Report Reviewers may make recommendations to TG for a Verification of
Corrective Action (VCA) audit. • Reasonable actions shall be taken to schedule, conduct and close the VCA audit to
minimize impact on total audit cycle time. • The VCA and related audit review are subject to failure when one or more Major
NCRs are issued. • Task Group completes review of each NCR and dispositions (NCR Status) • Discuss results with PRI • Items requiring TG resolution must be resolved by the TG prior to
acceptance/closure of the audit.
30
Submit C/A package
Review C/A package
Industry Working Together
Finding(s)
eAuditNet Accredit Supplier
Approve PRI Auditor
Selection
Contract Auditor
Recommend Auditor
Supplier Request*
Plan/ Schedule
Audits
Establish
Audit
Criteria
Primes/OEMs Suppliers’ Feedback
PRI Staff
Review & Accept C/A
Perform Audit
Audit Checklist
Industry experts manage all key steps
Shared Program Management
Audit Conducted
Audit Results
Corrective Actions
Process Evaluation/ Improvement
Auditor Qualification & Selection
Accreditation
eAuditNet
33
“An Online system for everything relating to audits” • eAuditNet Users
– Suppliers • Request a quote • Schedule an audit • Download checklists for self-audits • View supplier advisories • View supplier-related Nadcap procedures
– Subscribers • Monitor the real-time progress of suppliers • Lookup supplier checklists, NCRs, and Supplier and TG NCR responses • Look at current audit status of supplier
– Auditors • Communicate their availability for audits • View scheduled audits • Lookup audit details of a supplier’s past audits • Complete audit checklists and NCRs electronically for review • File reports on completed audits
• eAuditNet Tools – Qualified Manufacturer’s List
• A searchable list of certified Nadcap Suppliers available in eAuditNet
– Qualified Products List • A searchable list of manufacturers who have received a PRI product qualification approval letter
to a specific standard
– Online Registrar • PRI Registrar’s Directory of Registered Suppliers/Organizations.
Industry-Managed Program
• A process run by Nadcap Operation Procedures (NOPs)
• Task Group OPs are developed by NMC
• Nadcap Management Council – Ethics and Appeals Committee
– Oversight Committee
– Metrics Committee
– Standardization Committee
– Nadcap Vision Sub-team
34
Streamlined Requirements
One industry requirement
Multiple
Customer
Requirements
Reduced Number of Audits
Individual
Customer
Audits
One Audit
Quality Improvements for Suppliers (Supplier Support Committee 2009 Survey Results)
An increasing percentage of Nadcap accredited companies report quality improvement in the area(s) related to their Nadcap accreditation(s).
25%
77% 76%
83%
0%
20%
40%
60%
80%
100%
2003 2005 2007 2009
Quality Increase
2003 2005 2007 2009
Agenda
Nadcap Overview
• Criteria for Membership
• Membership Responsibilities
• Membership Benefits
• Membership Cost
Criteria for Membership
• Nadcap Subscriber Prime members must be:
– Production and Design Approval holders (such as Technical Standard Order [TSO], Type Certificate [TC], Production Certificate [PC] holders)
– Certified by their regulatory agency
• These Subscriber Members have the design authority to write their own special process specifications and have internal engineering organizations to provide technical directions and support.
Agenda
Nadcap Overview
Criteria for Membership
• Membership Responsibilities
• Membership Benefits
• Membership Cost
Membership Responsibilities
• User members are required to attend Nadcap meetings. If the
member is unable to attend, an alternate shall be designated.
• Reply to surveys, questionnaires and ballots that are circulated to
members.
• Carry through sponsorship and coordination of individual projects as
assigned.
• Prepare checklists for auditing and continuing surveillance.
• Review resumes and interview auditors.
• Review audit reports.
Agenda
Nadcap Overview
Criteria for Membership
Membership Responsibilities
• Membership Benefits
• Membership Cost
Membership Benefits • Directly involved in the establishment of the audit criteria (industry
standards & prime requirements)
– Audit Criteria (AC): Document containing checklists or other surveillance tools to
be utilized in the course of determining compliance to established industry
standards and prime requirements. • i.e. NDT: AC7114, AC7114/1, AC7114/2, AC7114/3 & AC7114/4
• Directly involved in the selection, interview process & performance
evaluation of the Auditors.
– Nadcap auditors have a highly skilled technical background with average of 30
years experience in the Special process audited
– Nadcap auditor goal is to evaluate and report the technical competency and
compliance of the supplier
– Currently NDT has 39 qualified auditors (21 are European Auditors)
Membership Benefits (continued)
• Directly involved in the audit report review process (receive supplier advisory notifications)
– Two-step review process:
1. Staff Engineer Review – Reviews for Completeness
– Clarification Changes (electronically) - Contact Auditors for Clarification
– Review Supplier Corrective Action
– Audit Report Package is submitted via eAuditNet for Task Group Review
2. Task Group Review – Reviews for Correctness
– Task Group decides Procedure for Review (Sub-group review, entire Task Group Review)
– Technical Comments, Supplier Responses, Technical Completeness, Auditor Summary Letter, Identify Additional Findings
– Completes Review of Each NCR and dispositions (NCR Status) – Task Group Votes on Accreditation via On-Line Balloting
• Cost Advantage – reduces costs through improved standardization.
At the same time a web poll asked: Do you believe that Nadcap
contributes to the overall aerospace industry’s safety record?
69% 31%
Yes
No
198 responses
45
Benefits of Nadcap to Industry
Mandated Program
Nadcap Prime Member Perspective 1
46
“Work together... to right size our processor base and
continually improve certification and oversight...
A quality initiative that will lead overall industry cost reductions.”
Nadcap Prime Member Perspective 2
47
“The objective is to have a
high performing self
managed supply base”
Agenda
Nadcap Overview
Criteria for Memebership
Membership Responsibilities
Membership Benefits
• Membership Cost
Annual Subscription Fees
• The annual subscription fee is based on the number of programs (commodities) the User may subscribe to and which option they choose: 1. Option A (Only available to Subscribers within North
America and Europe) • Air Travel/Hotel Costs are included per User member
attending a regular Nadcap meeting for any Task Group subscribed.
• 13 Primes subscribe to Option A
2. Option B • Air Travel/Hotel Costs are not included and covered by the
Subscriber.
Subscription Fees
Future Nadcap Meetings
18 – 23 October 2011
Register online @ www.PRI-Network.org
Date Location
20-24 February, 2012 San Diego, CA USA
25-29 June, 2012 Berlin, Germany
22-26 October, 2012 Pittsburgh, PA USA
• Primes and Suppliers network among industry peers
• Participation in free training
• Task Groups work on technical matters (audit checklists)
• Continual improvements made to program
• Nadcap Management Council creates Policy
• Engage with existing and potential customers
Questions
52